Patent Application
20200200280
This application is based upon and claims the benefit of priority of the prior Japanese Patent Application No. 2018-240888, filed on Dec. 25, 2018, the entire contents of which are incorporated herein by reference.
The present invention relates to a valve.
The valve to be used in atomic power plants includes a valve box seat portion to function as a valve seat in a valve box and a valve element seat portion to function as a valve seat on a valve element, and the valve box seat portion and the valve element seat portion are formed of a material excellent in abrasion resistance and erosion resistance.
The valve box seat portion and the valve element seat portion are formed of a build-up material of a Co-based alloy, for example. However, in this case, in the atomic power plant, the Co-based alloy comes into contact with high-temperature and high-pressure water, and thus a Co component is sometimes eluted into a reactor water from the Co-based alloy. Further, at the time of an opening and closing operation of the valve, the Co-based alloys slide on each other to be abraded, and thus the abraded Co component is sometimes mixed into the reactor water. The Co component turns into Co60 being a radioisotope in a reactor core and Co60 attaches to pieces of equipment such as a pipe and a turbine in some cases. As a result, in the working of a periodical inspection of a boiling water plant, it sometimes becomes difficult to reduce an exposure dose. Therefore, in order to reduce the amount of the Co component to enter the reactor water, using a cobalt-free material not containing a Co component has been considered.
For example, as the combination of the build-up material of the valve box seat portion and the build-up material of the valve element seat portion, for example, a combination of a Cr—Ni—Fe-based Fe base precipitation-type alloy and a Cr—Nb—Mo—Ni-based Ni base alloy has been proposed. However, in this case, it is impossible to easily execute a precipitation hardening heat treatment to be executed after welding of the build-up material.
Further, in the case where the build-up material of the valve box seat portion and the build-up material of the valve element seat portion both are the Ni base alloy, the both are the same in hardness, and thus it is difficult to suppress occurrence of the abrasion caused by sliding. In this case, in the boiling water plant, the attachment of Co60 decreases, leading to a decrease in the exposure dose, but in a pressurized water plant, a Ni component attaches to a steam generator, and thus it is not easy to reduce the exposure dose in an inspection work of a steam generator.
Furthermore, when exchanging the valve box seat portion in a valve that has already been installed in the plant, it is necessary to exchange the entire value including a valve box. Therefore, there is a possibility that works such as a work to cut off the valve connected to a pipe and a welding work are required.
As described above, the abrasion resistance and the erosion resistance of the valve box seat portion and the valve element seat portion in the valve are not sufficient in some cases. Therefore, it is not easy to reduce the exposure dose in the inspection work and so on in the atomic power plant.
Thus, a problem to be solved by the present invention is to provide a valve excellent in sliding characteristics that is capable of improving abrasion resistance and erosion resistance of a valve box seat portion and a valve element seat portion.
A valve in an embodiment includes: a valve box in which valve box seat portions are provided; and a valve element on which valve element seat portions are provided. One of the valve box seat portion and the valve element seat portion is formed of a build-up material of a Co-based alloy and the other of the valve box seat portion and the valve element seat portion is formed of a build-up material of an Fe-based alloy. Then, a Vickers hardness of the build-up material of the Co-based alloy is larger than a Vickers hardness of the build-up material of the Fe-based alloy, and a difference in the Vickers hardness between the build-up material of the Co-based alloy and the build-up material of the Fe-based alloy is HV50 or more.
According to the present invention, it is possible to provide a valve excellent in sliding characteristics that is capable of improving abrasion resistance and erosion resistance of a valve box seat portion and a valve element seat portion.
As illustrated in
[A-1] Valve Box 11
The valve box 11 includes, as illustrated in
[A-2] Valve Cover 12
The valve cover 12 is, as illustrated in
[A-3] Valve Rod 13
The valve rod 13, as illustrated in
[A-4] Valve Element 14
The valve element 14 is, as illustrated in
[A-5] Valve Driving Device 21
The valve driving device 21 is, as illustrated in
Concretely, when executing a closing operation of the valve 10, the valve driving device 21 moves the valve element 14 placed at the valve rod 13 downward, to thereby close the flow path being the internal space 11S. In contrast to this, when executing an opening operation of the valve 10, the valve driving device 21 moves the valve element 14 placed at the valve rod 13 upward, to thereby open the flow path being the internal space 11S.
[B-1] Valve Box Seat Portion 111
As illustrated in
In this embodiment, two valve box seat portions 111 are provided in the valve box 11. Concretely, one valve box seat portion 111 is placed in an upper side portion of the internal space 11S and the other valve box seat portion 111 is placed in a lower side portion of the internal space 11S. Further, in this embodiment, the valve box seat portion 111 is formed on an inner surface of an annular member 112 and the annular member 112 is fixed to an inner surface of the valve box 11.
[B-1] Valve Element Seat Portion 141
Then, as illustrated in
In this embodiment, two valve element seat portions 141 are provided on the valve element 14. Concretely, one valve element seat portion 141 is placed on an upper side portion of the valve element 14 and the other valve element seat portion 141 is placed on a lower side portion of the valve element 14.
As illustrated in
One of the valve box seat portion 111 and the valve element seat portion 141 is formed of a build-up material of a Co-based alloy. Then, the other of the valve box seat portion 111 and the valve element seat portion 141 is formed of a build-up material of an Fe-based alloy. That is, when the valve box seat portion 111 is formed of the build-up material of the Co-based alloy, the valve element seat portion 141 is formed of the build-up material of the Fe-based alloy. In contrast to this, when the valve element seat portion 141 is formed of the build-up material of the Co-based alloy, the valve box seat portion 111 is formed of the build-up material of the Fe-based alloy.
[C-1] Composition of the Fe-Based Alloy
The build-up material being the Fe-based alloy preferably has a chemical composition composed of, for example, in mass percentage, Cr of 23.0% or more and 26.0% or less, Mo of 1.8% or more and 2.2% or less, Si of 3.1% or more and 3.5% or less, C of 1.10% or more and 1.35% or less, Ni of 3.7% or more and 5.0% or less, Mn of 4.0% or more and 5.0% or less, B of 0% or more and less than 0.002%, S of 0% or more and less than 0.01%, P of 0% or more and less than 0.020%, N of 0% or more and less than 0.18%, and the balance composed of Fe and inevitable impurities.
There will be explained the reason why the main chemical components of the Fe-based alloy are set to fall within the above-described ranges.
In the Fe-based alloy, Cr is a component necessary for maintaining corrosion resistance. However, when the content ratio of Cr increases excessively, abrasion resistance sometimes decreases. Therefore, the content ratio of Cr is set to fall within the above-described range.
In the Fe-based alloy, Si is added in order to improve hardness and abrasion resistance. However, when the content ratio of Si increases excessively, weld cracking sometimes occurs. Therefore, the content ratio of Si is set to fall within the above-described range.
In the Fe-based alloy, C is added in order to improve hardness and abrasion resistance and stabilize austenite. However, when the content ratio of C increases excessively, weld cracking susceptibility sometimes increases. Therefore, the content ratio of C is set to fall within the above-described range.
In the Fe-based alloy, Ni is added as an austenite stabilizing element, and effects of improving weldability and the like are obtained. However, when the content ratio of Ni increases excessively, decreases in hardness and abrasion resistance sometimes occur. Therefore, the content ratio of Ni is set to fall within the above-described range.
In the Fe-based alloy, Mn is added as an austenite stabilizing element. However, when the content ratio of Mn increases excessively, weld cracking susceptibility may be exhibited. Therefore, the content ratio of Mn is set to fall within the above-described range.
[C-2] Composition of the Co-Based Alloy
As the Co-based alloy, for example, stellite (registered trademark) can be used. Concretely, the build-up material being the Co-based alloy preferably has a chemical composition composed of, for example, in mass percentage, Cr of 25.0% or more and 32.0% or less, Mo of 0% or more and 1.0% or less, Si of 0% or more and 2.0% or less, C of 0.70% or more and 1.40% or less, Ni of 0% or more and 3.0% or less, Fe of 0% or more and 5.0% or less, Mn of 0% or more and 2.0% or less, W of 3.0% or more and 6.0% or less, S of 0% or more and 0.03% or less, P of 0% or more and 0.03% or less, and the balance composed of Co and inevitable impurities.
[D-1] Difference in Vickers Hardness
In this embodiment, the Vickers hardness of the build-up material of the Co-based alloy is larger than that of the build-up material of the Fe-based alloy, and the difference in the Vickers hardness between the build-up material of the Co-based alloy and the build-up material of the Fe-based alloy is HV50 or more. The Vickers hardness can be found by a test method described in “JIS Z 2244: 2009 Vickers hardness test.”
[D-2] Vickers Hardness of the Build-Up Material of the Fe-Based Alloy
The build-up material of the Fe-based alloy preferably has a Vickers hardness of HV380 or more and HV400 or less. When the Vickers hardness is less than the lower limit value of the above-described range, abrasion is likely to occur in the build-up material of the Fe-based alloy, and thus the decrease in the abrasion resistance sometimes occurs. In contrast to this, when the Vickers hardness is greater than the upper limit value of the above-described range, abrasion is likely to occur in the build-up material of the Co-based alloy, and thus an abraded component of the Co-based alloy is sometimes mixed into the reactor water. Additionally, when the Vickers hardness of the build-up material of the Fe-based alloy is out of the above-described range, weld cracking or the like sometimes occurs when the Fe-based alloy is formed.
When the valve box seat portion 111 or the valve element seat portion 141 is formed of the build-up material of the Fe-based alloy, for example, a powder of the Fe-based alloy having the above-described chemical composition is used to execute a build-up operation. Here, the build-up operation is preferably executed by plasma transferred arc welding (PTA welding) or a hot isostatic pressing method (HIP method), for example.
Then, when the valve box seat portion 111 or the valve element seat portion 141 is formed of the build-up material of the Co-based alloy, for example, a powder of the Co-based alloy having the above-described chemical composition is used to execute a build-up operation. Here, the build-up operation is preferably executed by a gas build-up welding method, for example.
As above, in this embodiment, one of the valve box seat portion 111 and the valve element seat portion 141 is formed of the build-up material of the Co-based alloy. In contrast to this, the other of the valve box seat portion 111 and the valve element seat portion 141 is formed of the build-up material of the Fe-based alloy. Here, the Vickers hardness of the build-up material of the Co-based alloy is larger than that of the build-up material of the Fe-based alloy and the difference in the Vickers hardness between the build-up material of the Co-based alloy and the build-up material of the Fe-based alloy is HV50 or more.
Therefore, in this embodiment, in an opening and closing operation of the valve 10, the Fe-based alloy is mainly abraded, and thus the abrasion of the Co-based alloy is suppressed, which will be described in detail later. This makes it possible to suppress mixing of the Co component into the reactor water, which is caused by abrasion of the Co-based alloy. As a result, the exposure dose to a worker is reduced in a periodical inspection work and so on of a light-water reactor plant, to thus enable an improvement in safety. Then, the abrasion resistance and the like in this embodiment are the same as those in the case where the valve box seat portion 111 and the valve element seat portion 141 are both formed by using the Co-based alloy, and thus this embodiment is good. Further, this embodiment is excellent in erosion resistance.
Furthermore, the sliding characteristics in this embodiment are the same as those in the case where the valve box seat portion 111 and the valve element seat portion 141 are both formed by using the Co-based alloy. Along with this, even in a state where a high contact pressure is added between the valve box seat portion 111 and the valve element seat portion 141, suitable sliding characteristics can be obtained between the valve box seat portion 111 and the valve element seat portion 141.
Besides, an existing valve is simply modified, thereby making it possible to obtain the valve 10 in this embodiment. For example, in the case of the valve box seat portion 111 and the valve element seat portion 141 both formed by using the Co-based alloy, one of the valve box seat portion 111 and the valve element seat portion 141 is replaced with one formed of the build-up material of the Fe-based alloy, and thereby the valve 10 in this embodiment can be obtained.
In the above-described embodiment, the case where the valve box seat portion 111 is formed on the inner surface of the annular member 112 and the annular member 112 is fixed to the inner surface of the valve box 11 has been explained. In this case, it is possible to manufacture the valve 10 easily and efficiently. However, the present invention is not limited to this. For example, it is also possible to directly form the valve box seat portion 111 on the inner surface of the valve box 11 without forming the valve box seat portion 111 on the inner surface of the annular member 112.
In the above-described embodiment, the case where the valve 10 is a sluice valve has been explained, but the present invention is not limited to this. In the same manner as in the above-described embodiment, the valve box seat portions and the valve element seat portions may be configured in valves in other forms such as a globe valve, a check valve, a safety valve, a ball valve, and a butterfly valve.
Hereinafter, there will be explained an example and so on while using Table 1,
In Example 1, as illustrated in Table 1, the Fe-based alloy was built-up by PTA welding, to thereby form the valve element seat portion 141. Then, the Co-based alloy was built-up by gas build-up welding, to thereby form the valve box seat portion 111.
In Example 1, the Vickers hardness of the valve element seat portion 141 was 380HV, the Vickers hardness of the valve box seat portion 111 was 430HV, and the difference in the Vickers hardness between the both was 50HV. The above-described Vickers hardnesses are the values measured by a test method in conformity with JIS Z 2244. Here, the measurement of the Vickers hardness was performed under the condition that an applied load of a diamond indenter was 10 kg.
A concrete manufacturing method will be explained below.
(Valve Element Seat Portion 141) In Example 1, the Fe-based alloy used for fabricating the valve element seat portion 141 is a material having a composition in mass percentage described below.
Then, the above-described Fe-based alloy was melted in a vacuum or under an inert gas environment, and then a powder of the Fe-based alloy was manufactured by a gas atomization method. Here, a powder of the Fe-based alloy having a particle size falling within a range of larger than 80 mesh and smaller than 325 mesh (+80/−325 mesh) was used.
Then, on an S25C (JIS G 4051: 2009) being a steel product, three-layer build-up welding was performed using the powder of the above-described Fe-based alloy by a PTA welding method, and thereby the valve element seat portion 141 for a sluice valve of 150A was fabricated as a sliding test piece.
(Valve Box Seat Portion 111)
In Example 1, the Co-based alloy used for fabricating the valve box seat portion 111 is a material having a composition in mass percentage described below.
Then, the above-described Co-based alloy was melted in a vacuum or under an inert gas environment, and then a powder of the Co-based alloy was manufactured by a gas atomization method. Here, similarly to the case of the powder of the above-described Fe-based alloy, a powder of the Co-based alloy having a particle size falling within a range of larger than 80 mesh and smaller than 325 mesh (+80/−325 mesh) was used.
Then, on an S25C (JIS G 4051: 2009) being a steel product, three-layer build-up welding was performed using the powder of the above-described Co-based alloy by a gas build-up welding method, and thereby the valve box seat portion 111 for the sluice valve of 150A was fabricated as a sliding test piece.
In Comparative example 1, as illustrated in Table 1, similarly to the case of Example 1, the Co-based alloy was built-up by gas build-up welding, to thereby form the valve box seat portion 111. In contrast to this, as for the formation of the valve element seat portion 141, the Co-based alloy was built-up by gas build-up welding unlike the case of Example 1. The formation of the valve element seat portion 141 was performed under the same condition as that of the formation of the valve box seat portion 111.
In Comparative example 1, the Vickers hardness of the valve box seat portion 111 and the Vickers hardness of the valve element seat portion 141 were both 430HV and the difference in the Vickers hardness between the both was 0HV.
In Comparative example 2, as illustrated in Table 1, similarly to the case of Example 1, the Fe-based alloy was built-up by PTA welding, to thereby form the valve element seat portion 141. In contrast to this, as for the formation of the valve box seat portion 111, the Fe-based alloy was built-up by PTA welding unlike the case of Example 1. The formation of the valve box seat portion 111 was performed under the same condition as that of the formation of the valve element seat portion 141.
In Comparative example 2, the Vickers hardness of the valve box seat portion 111 and the Vickers hardness of the valve element seat portion 141 were both 380HV and the difference in the Vickers hardness between the both was 0HV.
[Test Results]
(1) Leakage Amount (Sliding Test Using a Sliding Test Machine)
As illustrated in Table 1, a leakage amount in each of the examples was measured. Here, a sliding test was executed using a sliding test machine in order to measure the leakage amount. The sliding test was executed by performing an opening and closing operation of the valve a plurality of times under the condition of a contact pressure being 100 MPa in a saturated vapor at a temperature of 288° C.
Table 1 illustrates results of the leakage amount corresponding to the number of times of the opening and closing operation of the valve (the number of times of actuation).
As illustrated in Table 1, the leakage amount in Example 1 was almost equal to or smaller than that in Comparative example 1 and Comparative example 2.
In Example 1, as described above, the valve element seat portion 141 is formed of the build-up material of the Fe-based alloy whose Vickers hardness is 380HV and the valve box seat portion 111 is formed of the build-up material of the Co-based alloy whose Vickers hardness is 430HV. That is, in Example 1, the Vickers hardness of the build-up material of the Co-based alloy is larger than that of the build-up material of the Fe-based alloy, and the difference in the Vickers hardness between the build-up material of the Co-based alloy and the build-up material of the Fe-based alloy is HV50 or more. Therefore, in the sliding test, the Fe-based alloy is abraded more than the Co-based alloy, and thus the Co-based alloy ensures sealing performance. The Fe-based alloy has a body-centered cubic lattice structure, while the Co-based alloy has a hexagonal close-packed lattice structure, so that the Co-based alloy is thought to be more excellent in slidability than the Fe-based alloy. As a result, in Example 1, the amount of the Co-based alloy to be abraded decreases and entrance of the abraded Co-based alloy into the reactor is suppressed. Accordingly, it is possible to reduce the exposure dose due to the Co-based alloy in a periodical inspection work, and thus it is possible to shorten the working time and further improve the safety.
The number of times of actuation of the valve is about five times in one-cycle operation (13 months). The valve is overhauled every 10 years, and thus the number of times of actuation of the opening and closing operation to be performed by the time when the overhaul is performed is about 50 times. Then, as the number of times of actuation to be considered in designing, 100 times, which are twice as many as 50 times, are set. At this time, in Example 1, the leakage amount is 50 mL/min and is constant. In contrast to this, in Comparative example 1 used in a current system, the leakage amount tends to increase according to the number of times of actuation. Therefore, the increase in the leakage amount corresponding to the number of times of actuation is smaller in Example 1 than in Comparative example 1, and thus Example 1 is excellent.
In Comparative example 2, the difference in the Vickers hardness is zero similarly to Comparative example 1. In Comparative example 2, the leakage amount is larger than that in Example 1 and Comparative example 1. In Comparative example 2, when the number of times of the opening and closing operation (the number of times of actuation) is 50 times, the leakage amount is more than triple that in Example 1. Furthermore, when the number of times of the opening and closing operation is 100 times, the leakage amount is more than four times that in Example 1 and Comparative example 1.
(2) Friction Coefficient
As illustrated in
(3) Surface Roughness Ra
After the above-described sliding test was executed in each of the examples, the valve was disassembled, and each arithmetic average surface roughness Ra (JIS B 0601-2001) of sliding surfaces of the valve box seat portion 111 and the valve element seat portion 141 was measured.
In Example 1, results of the arithmetic average surface roughness Ra were as follows.
In Comparative example 1, results of the arithmetic average surface roughness Ra were as follows.
The results of the above-described arithmetic average surface roughness Ra reveal that maintenance of Example 1 is enabled similarly to Comparative example 1.
Separately from the above-described sliding test, a sliding test was performed on a sluice valve of 600 A and a sluice valve of 80 A. Results of the respective sliding tests are explained sequentially.
[Sliding Test on the Sluice Valve of 600 A]
The sliding test was executed on the sluice valve of 600 A in which the valve element seat portions 141 and the valve box seat portions 111 were formed similarly to the case of Example 1. The sliding test was executed by performing the opening and closing operation of the valve 50 times under the condition of a differential pressure being 7.13 MPa in a saturated vapor at a temperature of 288° C.
After the above-described sliding test, a valve seat leakage test was performed, to thereby confirm the presence or absence of leakage. The valve seat leakage test was executed by room temperature water under the condition of a test pressure being 8.62 MPa and a retention time being three minutes. As a result, no leakage was confirmed.
[Sliding Test on the Sluice Valve of 80 A]
The sluice valve of 80 A in which the valve element seat portions 141 and the valve box seat portions 111 were formed similarly to the case of Example 1 was placed in a pilot plant for 1.5 years. Then, the sliding test was further executed on the sluice valve. The sliding test was executed under the condition of a differential pressure being 11.5 MPa in a vapor at a temperature of 485° C. This condition satisfies system conditions in a pressurized water plant among atomic power plants.
After the above-described sliding test, the sluice valve was detached from the pilot plant and the valve seat leakage test was executed on the sluice valve, to thereby confirm the presence or absence of leakage. The valve seat leakage test was executed by room temperature water under the condition of a test pressure being 28.5 MPa and a retention time being one minute. As a result, no leakage was confirmed.
Further, as a result that an appearance inspection was performed, it was confirmed that no defect such as “galling” occurred in the seat portion. Furthermore, as a result that a liquid osmotic pressure inspection was performed, no PT (Penetrant Testing) flaw indication or cracking was confirmed.
After the above-described sliding test, results of the arithmetic average surface roughness Ra were as follows. These results reveal that a large amount of the Fe-based alloy was abraded, thus making it possible to limit the amount of Co to enter the reactor.
[Erosion Test]
In an erosion test, the Fe-based alloy was built-up by PTA welding under the same condition as that in Example 1, to thereby fabricate a test piece, and then machining was performed on the test piece, to thereby fabricate an erosion test piece 1. Further, the Co-based alloy was built-up by a gas build-up welding method under the same condition as that in Example 1, to thereby fabricate a test piece, and then machining was performed on the test piece, to thereby fabricate an erosion test piece 2.
Then, the erosion test was executed on each of the erosion test piece 1 of the Fe-based alloy and the erosion test piece 2 of the Co-based alloy. In the erosion test, a high-pressure running water was made to collide with each of the test pieces to cause erosion. Concretely, the erosion test was executed under the following test condition.
As illustrated in
<Others>
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2018-240888 | Dec 2018 | JP | national |
